U.S. patent application number 10/867816 was filed with the patent office on 2005-05-19 for method for producing molding compound resin tablet for wavelength conversion, and method for manufacturing white light emitting diode by using the production method.
Invention is credited to Ahn, Doo Hoon, Lee, Seon Goo, Yoon, Joon Ho.
Application Number | 20050104244 10/867816 |
Document ID | / |
Family ID | 34567821 |
Filed Date | 2005-05-19 |
United States Patent
Application |
20050104244 |
Kind Code |
A1 |
Yoon, Joon Ho ; et
al. |
May 19, 2005 |
Method for producing molding compound resin tablet for wavelength
conversion, and method for manufacturing white light emitting diode
by using the production method
Abstract
Disclosed herein is a method for producing a molding compound
resin tablet for wavelength conversion. The method comprises the
steps of wet-dispersing a phosphor powder in a translucent liquid
resin to form a molding compound resin body in which the phosphor
powder is dispersed, and grinding the molding compound resin body
into a powder form and applying a predetermined pressure to the
resin powder. Further disclosed is a method for manufacturing a
white light emitting diode using the molding compound resin tablet
by a transfer molding process.
Inventors: |
Yoon, Joon Ho; (Seoul,
KR) ; Lee, Seon Goo; (Gunpo, KR) ; Ahn, Doo
Hoon; (Yongin, KR) |
Correspondence
Address: |
LOWE HAUPTMAN GILMAN AND BERNER, LLP
1700 DIAGONAL ROAD
SUITE 300 /310
ALEXANDRIA
VA
22314
US
|
Family ID: |
34567821 |
Appl. No.: |
10/867816 |
Filed: |
June 16, 2004 |
Current U.S.
Class: |
264/115 ;
264/140; 264/259; 264/349 |
Current CPC
Class: |
H01L 2224/48091
20130101; H01L 2224/8592 20130101; Y02B 20/181 20130101; C09K 11/08
20130101; H01L 2933/0041 20130101; H01L 2224/48257 20130101; Y02B
20/00 20130101; H01L 2924/181 20130101; C09K 11/02 20130101; H01L
2224/48247 20130101; H01L 2224/48091 20130101; H01L 2924/00014
20130101; H01L 2924/181 20130101; H01L 2924/00012 20130101 |
Class at
Publication: |
264/115 ;
264/140; 264/349; 264/259 |
International
Class: |
B29B 009/12; B29B
013/10 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 19, 2003 |
KR |
2003-82136 |
Claims
What is claimed is:
1. A method for producing a molding compound resin tablet for
wavelength conversion in which a phosphor converting at least a
portion of wavelengths is uniformly dispersed, comprising the steps
of: wet-dispersing a phosphor powder in a translucent liquid resin
to form a molding compound resin body in which the phosphor powder
is dispersed; and grinding the molding compound resin body into a
powder form, and applying a predetermined pressure to the resin
powder.
2. The method according to claim 1, wherein the step of forming the
molding compound resin body includes the sub-steps of: mixing the
translucent liquid resin, a material containing at least a curing
agent and the phosphor powder; kneading the mixture in a gel state;
and stabilizing the kneaded mixture to form the molding compound
resin body containing the phosphor.
3. The method according to claim 2, wherein the kneading is carried
out at a temperature between about 100.degree. C. and about
120.degree. C., and the formation of the molding compound resin
body is carried out by quenching the kneaded mixture.
4. The method according to claim 2, further comprising the sub-step
of roll-milling the kneaded mixture after the kneading and before
the stabilization.
5. The method according to claim 2, wherein, in the mixing step,
the phosphor powder is simultaneously mixed with the translucent
liquid resin and the material containing at least a curing
agent.
6. The method according to claim 2, wherein, in the mixing step,
the translucent liquid resin and the phosphor powder are first
mixed (1st mixing), and then the material containing at least a
curing agent is added to the mixture and mixed (2nd mixing).
7. The method according to claim 2, wherein, in the mixing step,
the translucent liquid resin and the material containing at least a
curing agent are first mixed (1st mixing), and then the phosphor
powder is added to the mixture (2nd mixing).
8. The method according to claim 7, wherein the 2nd mixing is
carried out by adding at least one agent selected from a catalyst
and a coupling agent together with the phosphor powder, and
mixing.
9. The method according to claim 8, wherein at least one agent
selected from a catalyst and a coupling agent and the phosphor
powder are added in a mixture form obtained by the same milling
process.
10. The method according to claim 2, wherein the step of forming
the molding compound resin body containing the phosphor is carried
out by mixing the translucent liquid resin and the material
containing at least a curing agent to form a gelled mixture,
kneading the gelled mixture and the phosphor powder, and
stabilizing the kneaded mixture to form the molding compound resin
body.
11. The method according to claim 10, wherein the kneading is
carried out at a temperature between about 100.degree. C. and about
120.degree. C., and the formation of the molding compound resin
body is carried out by quenching the kneaded mixture.
12. The method according to claim 10, further comprising the
sub-step of roll-milling the kneaded mixture after the kneading and
before the stabilization.
13. The method according to claim 1, wherein the phosphor includes
at least one element selected from the group consisting of Y, Lu,
Sc, La, Gd, Ce and Sm, and at least one element selected from the
group consisting of Al, Ga and In.
14. The method according to claim 1, wherein the translucent liquid
resin is an epoxy resin.
15. A method for manufacturing a white light emitting diode molded
with a molding compound resin for wavelength conversion in which
the phosphor converting at least a portion of wavelengths is
uniformly dispersed, the method comprising the steps of:
wet-dispersing a phosphor powder in a translucent liquid resin to
form a molding compound resin body in which the phosphor powder is
dispersed; grinding the molding compound resin body into a powder
form, and applying a predetermined pressure to the resin powder to
produce a molding compound in a tablet form; and transfer-molding
the molding compound tablet on a package structure on which a blue
or UV light emitting diode is mounted.
16. The method according to claim 15, wherein the step of forming
the molding compound resin body includes the sub-steps of: mixing
the translucent liquid resin, a material containing at least a
curing agent and the phosphor powder; kneading the mixture in a gel
state; and stabilizing the kneaded mixture to form the molding
compound resin body containing the phosphor.
17. The method according to claim 16, wherein the kneading is
carried out at a temperature between about 100.degree. C. and about
120.degree. C., and the formation of the molding compound resin
body is carried out by quenching the kneaded mixture.
18. The method according to claim 16, further comprising the
sub-step of roll-milling the kneaded mixture after the kneading and
before the stabilization.
19. The method according to claim 16, wherein, in the mixing step,
the phosphor powder is simultaneously mixed with the translucent
liquid resin and the material containing at least a curing
agent.
20. The method according to claim 16, wherein, in the mixing step,
the translucent liquid resin and the phosphor powder are first
mixed (1st mixing), and then the material containing at least a
curing agent is added to the mixture and mixed (2nd mixing).
21. The method according to claim 16, wherein, in the mixing step,
the translucent liquid resin and the material containing at least a
curing agent are first mixed (1st mixing), and then the phosphor
powder is added to the mixture (2nd mixing).
22. The method according to claim 21, wherein the 2nd mixing is
carried out by adding at least one agent selected from a catalyst
and a coupling agent together with the phosphor powder, and
mixing.
23. The method according to claim 21, wherein at least one agent
selected from a catalyst and a coupling agent and the phosphor
powder are added in a mixture form obtained by the same milling
process.
24. The method according to claim 16, wherein the step of forming
the molding compound resin body containing the phosphor is carried
out by mixing the translucent liquid resin and the material
containing at least a curing agent to form a gelled mixture,
kneading the gelled mixture and the phosphor powder, and
stabilizing the kneaded mixture to form the molding compound resin
body.
25. The method according to claim 24, wherein the kneading is
carried out at a temperature between about 100.degree. C. and about
120.degree. C., and the formation of the molding compound resin
body is carried out by quenching the kneaded mixture.
26. The method according to claim 24, further comprising the
sub-step of roll-milling the kneaded mixture after the kneading and
before the stabilization.
27. The method according to claim 15, wherein the phosphor includes
at least one element selected from the group consisting of Y, Lu,
Sc, La, Gd, Ce and Sm, and at least one element selected from the
group consisting of Al, Ga and In.
28. The method according to claim 15, wherein the translucent
liquid resin is an epoxy resin.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method for manufacturing
a white light emitting diode, and more particularly to a method for
producing a molding compound resin tablet for wavelength conversion
which is capable of ensuring uniform distribution of a phosphor and
a method for manufacturing a white light emitting diode by using
the production method.
[0003] 2. Description of the Related Art
[0004] Generally, since light emitting diodes (LEDs) have
advantages in terms of monochromatic peak wavelengths, a high light
efficiency and a small size, light efficiency and miniaturization,
they have been widely used as display devices and light sources.
Among these LEDs, white, light emitting diodes are progressively
utilized as high output and high efficiency light sources which can
replace backlights of illuminators or display devices.
[0005] Such white light emitting diodes are predominantly
manufactured by a wavelength conversion process wherein a phosphor
is applied onto a blue or UV light emitting diode to convert the
blue or UV light to white light.
[0006] FIG. 1 is a cross-sectional view of a white light emitting
diode package 10 fabricated in accordance with a conventional
method.
[0007] Referring to FIG. 1, the white light emitting diode package
10 comprises two lead frames 3 and 4, a blue light emitting diode 5
mounted on a cap 3a of the lead frame 3, and a transparent molding
portion 8 formed on the lead frames 3 and 4. Both electrodes of the
blue light emitting diode 5 are electrically connected to wires 6
and 7, which are connected to lead frames 3 and 4,
respectively.
[0008] A resin 9 including a Y--Al--Ga (YAG)-based phosphor is
molded inside the cap 3a formed on the lead frames 4 so as to
surround the blue LED 5. The blue LED 5 emitting blue light can
produce the desired white light by combining a portion of light
excited into yellowish green light having a peak wavelength of 555
nm and a portion of blue light directly emitted from the LED.
[0009] Commonly, the resin 9 containing the phosphor is formed on
the LED 5 by a dispensing process using a liquid resin.
[0010] However, the dispensing process is not suitable for
mass-production when compared to other molding processes. In
addition, since the dispensing process uses a liquid resin,
phosphor particles may be precipitated in the liquid resin during
curing of the liquid resin. The precipitation of the phosphor
particles causes non-uniform dispersion in the resin layer 9
surrounding the LED 5. The light converted from the resin layer 9
in which the phosphor is non-uniformly dispersed partially exhibits
a yellowish white or bluish white color, resulting in
non-uniformity in color.
[0011] In order to solve the above-mentioned problems of the prior
art, a white light emitting diode manufactured by a transfer
molding process is proposed in Korean Patent No. 348377, which was
issued on Jul. 9, 2002. According to this patent, as shown in FIG.
2, the white light emitting diode is manufactured by a method
comprising the steps of mixing a phosphor powder with a molding
compound resin powder, e.g., an epoxy molding compound powder (step
S21), shaping the mixture into a molding compound resin tablet
(step S25), and transfer-molding a blue light emitting diode using
the tablet (step S29) to manufacture the desired white light
emitting diode.
[0012] Since the method employs a transfer molding process having a
relatively short curing time, it has advantages that deterioration
in the light conversion efficiency due to the precipitation of
phosphor particles can be prevented, and at the same time, the
mass-production of the white light emitting diode can be
enhanced.
[0013] However, since the phosphor powder and the molding compound
resin powder having different specific gravities and particle sizes
are mixed with each other to produce the molding compound resin
tablet, it is difficult to realize uniform distribution of the
phosphor powder in the tablet.
[0014] Despite the advantages of the transfer molding process, the
white light emitting diode thus manufactured still emits yellowish
white or bluish white light, and thus it is difficult to
manufacture a light emitting diode having a high light conversion
efficiency.
SUMMARY OF THE INVENTION
[0015] Therefore, the present invention has been made in view of
the above problems, and it is an object of the present invention to
provide a method for producing a tablet containing a phosphor
powder wherein the phosphor powder is dispersed so as to maximize
the effects of a transfer molding process having a short curing
time.
[0016] It is another object of the present invention to provide a
method for manufacturing a white light emitting diode having good
white light emitting efficiency by using the method for producing a
tablet.
[0017] In order to accomplish the above objects of the present
invention, there is provided a method for producing a molding
compound resin tablet for wavelength conversion in which a phosphor
converting at least a portion of wavelengths is uniformly
dispersed, comprising the steps of: wet-dispersing a phosphor
powder in a translucent liquid resin to form a molding compound
resin body in which the phosphor powder is dispersed; and grinding
the molding compound resin body into a powder form, and applying a
predetermined pressure to the resin powder.
[0018] The wet dispersion process employed in the method of the
present invention is performed depending on the addition time of
the phosphor powder.
[0019] In one embodiment of the present invention, the step of
forming the molding compound resin body includes the sub-steps of:
mixing the translucent liquid resin, a material containing at least
a curing agent and the phosphor powder; kneading the mixture in a
gel state; and stabilizing the kneaded mixture to form the molding
compound resin body containing the phosphor.
[0020] Preferably, the kneading is carried out at a temperature
between about 100.degree. C. and about 120.degree. C., and the
formation of the molding compound resin body is carried out by
quenching the kneaded mixture.
[0021] Following the kneading, the step of forming the molding
compound resin body may further include a sub-step of roll-milling
the kneaded mixture to further disperse the phosphor prior to
stabilizing.
[0022] More specifically, the phosphor powder may be simultaneously
mixed with the translucent liquid resin and the material containing
at least a curing agent. Alternatively, the translucent liquid
resin and the phosphor powder are first mixed (1st mixing), and
then the material containing at least a curing agent is added to
the mixture and mixed (2nd mixing). Alternatively, the translucent
liquid resin and the material containing at least a curing agent
are first mixed (1st mixing), and then the phosphor powder is added
to the mixture and mixed (2nd mixing).
[0023] In the case where the phosphor powder is mixed in the 2nd
mixing, at least one agent selected from a catalyst and a coupling
agent is added together with the phosphor powder. In this
embodiment, it is preferred that at least one agent selected from a
catalyst and a coupling agent and the phosphor powder are added in
a mixture form obtained by the same milling process.
[0024] The wet dispersion process employed in the method of the
present invention is accomplished by mixing the translucent liquid
resin and the material containing at least a curing agent to
partially proceed a reaction to form a gelled mixture, adding the
phosphor powder thereto and kneading the mixture.
[0025] The phosphor may be a fluorescent material including at
least one element selected from the group consisting of Y, Lu, Sc,
La, Gd, Ce and Sm, and at least one element selected from the group
consisting of Al, Ga and In. A representative example of the
translucent liquid resin is an epoxy resin.
[0026] In accordance with another aspect of the present invention,
there is provided a method for manufacturing a white light emitting
diode by using the production method of the tablet described
above.
[0027] Specifically, the method for manufacturing a white light
emitting diode comprises the steps of: wet-dispersing a phosphor
powder in a translucent liquid resin to form a molding compound
resin body in which the phosphor powder is dispersed; grinding the
molding compound resin body into a powder form, and applying a
predetermined pressure to the resin powder to produce a molding
compound in a tablet form; and transfer-molding the molding
compound tablet on a package structure on which a blue or UV light
emitting diode is mounted. The white light emitting diode thus
manufactured is molded with the molding compound resin for
wavelength conversion in which the phosphor converting at least a
portion of wavelengths is uniformly dispersed.
[0028] The method of the present invention is characterized in that
a wet dispersion process using a translucent liquid resin is
employed to produce a molding compound resin tablet, instead of
simple mixing of powders, thereby ensuring uniform dispersion of a
phosphor powder in the molding compound resin tablet. The wet
dispersion process can be realized by a mixing process for the
formation of a molding compound resin body, without the need for
further processing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] The above and other objects, features and other advantages
of the present invention will be more clearly understood from the
following detailed description taken in conjunction with the
accompanying drawings, in which:
[0030] FIG. 1 is a side cross-sectional view of a conventional
white light emitting diode;
[0031] FIG. 2 is a flow chart schematically illustrating a
conventional method for manufacturing a white light emitting
diode;
[0032] FIG. 3 is a graph showing change in the curing rate (%) with
respect to each step of a method for producing a molding compound
resin tablet for wavelength conversion according to the present
invention;
[0033] FIGS. 4 to 6 are flow charts schematically illustrating
embodiments of a method for producing a molding compound resin
tablet for wavelength conversion according to the present
invention;
[0034] FIG. 7 is a side cross-sectional view of a white light
emitting diode manufactured by a method of the present invention;
and
[0035] FIGS. 8a and 8b are color coordinates of a white light
emitting diode manufactured by a conventional method and a white
light emitting diode manufactured by a method of the present
invention, respectively.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] The present invention will now be described in more detail
with reference to the accompanying drawings.
[0037] FIG. 3 is a graph showing change in the curing rate (%) with
respect to each step of a method for producing a molding compound
resin tablet for wavelength conversion according to the present
invention. Referring to FIG. 3, morphologies of each step as the
curing reaction progresses are schematically shown. It is
understood that FIG. 3 and the following description will help in
determining the time and conditions for wet dispersion of a
phosphor powder.
[0038] First, a translucent liquid resin such as an epoxy resin and
a curing agent are mixed with each other (stage A1). Specifically,
the translucent liquid resin and the curing agent undergo a curing
reaction (curing rate: >10%), and are then mixed with each other
using a mixer (stage A2). The curing rate is increased to a level
of 40% to form a gel having a uniform fluidity. At this mixing
step, an additive such as a catalyst or a coupling agent may be
additionally added.
[0039] Thereafter, the gelled mixture is subjected to a kneading
process (B) for more uniform mixing. At this step, the mixture is
melt-mixed at a temperature capable of maintaining the gel
state.
[0040] A phosphor powder can be wet-dispersed in the mixture for
forming a molding compound resin body at stages A1, A2 and (or) B.
At these stages, since the mixture for forming a molding compound
resin body is maintained in a liquid or gel state, the phosphor
powder can be uniformly dispersed in an effective manner. That is,
since the phosphor powder is added during mixing of the translucent
liquid resin and the curing agent in a liquid state or kneading of
the gelled mixture, the phosphor powder can be much more uniformly
dispersed than when in a powder form.
[0041] This dispersion of the phosphor powder can be performed by a
conventional mixing and/or kneading process for the formation of a
molding compound resin body, without the need for further
processing.
[0042] Next, the mixture is quenched to form a molding compound
resin body in a solid state. The molding compound resin body is
then ground into a powder, and is then pressurized to produce a
molding compound resin tablet in which the phosphor is uniformly
dispersed. At this step, the molding compound resin tablet is in a
stable state in which no curing reaction is progressed (stage
C).
[0043] The molding compound resin tablet produced by the method of
the present invention can be completely cured for a relatively
short curing time by a transfer molding process for manufacturing a
white light emitting diode (represented by a dashed line in stage
D). Since the transfer molding process using the tablet requires a
curing time shorter than a dispensing process using a common liquid
resin, little or no precipitation of the phosphor particles already
uniformly dispersed in the molding compound tablet takes place,
thus forming a layer exhibiting high wavelength conversion
efficiency.
[0044] As described above with reference to FIG. 3, since the
phosphor powder is mixed with a mixture in a liquid or gel state,
it can be effectively dispersed in the molding compound resin
tablet. In addition, the method of the present invention can be
variously performed depending on the addition time of the phosphor
powder.
[0045] FIGS. 4 to 6 illustrate various embodiments of the method
for producing a molding compound resin tablet for wavelength
conversion according to the present invention.
[0046] FIG. 4 shows an embodiment wherein a translucent liquid
resin, a curing agent and a phosphor are simultaneously added and
mixed.
[0047] The method of the present embodiment begins from the step of
mixing a translucent liquid resin, a material containing at least a
curing agent and a phosphor powder (step S41). More specifically,
the phosphor powder is first mixed with the translucent liquid
resin and then the curing agent is added to the mixture, and vice
versa. Alternatively, the translucent liquid resin, the curing
agent and the phosphor powder may be simultaneously added and
mixed. Through these mixing processes, the phosphor powder can be
uniformly dispersed in the translucent liquid resin as a base
resin.
[0048] The phosphor is a material containing at least one element
selected from the group consisting of Y, Lu, Sc, La, Gd, Ce and Sm,
and at least one element selected from the group consisting of Al,
Ga and In. A representative example of the phosphor is a YAG-based
phosphor. For more uniform dispersion, the phosphor employed in the
present invention is preferably in the form of a powder having an
average particle diameter of 5.about.50 microns.
[0049] In step S43, an additive for forming a molding compound
resin may be further mixed. Examples of suitable additives include
curing catalysts, coupling agents, release agents and modifying
agents already known in the art. For more uniform mixing, these
additives are formed into a powder through a milling-process, and
are then added to the mixture.
[0050] Next, the resulting mixture is subjected to a kneading
process in a gel state (step S44). The kneading process refers to a
process wherein a mixture cured to some extent is uniformly mixed
at a temperature sufficient to maintain the gel state. The kneading
process is preferably performed at a temperature between about
100.degree. C. and about 120.degree. C.
[0051] Subsequently, the resulting kneaded mixture is stabilized to
form a molding compound resin body containing the phosphor (step
S45). The molding compound resin body thus formed is a solid state
resin in which the phosphor powder is uniformly dispersed through
the mixing and the kneading processes. At this step, the mixture
kneaded at high temperature is quenched. Prior to the quenching,
i.e. stabilization, the kneaded mixture may be subjected to a
rolling process in order to pursue uniform dispersion of the
phosphor powder.
[0052] The molding compound resin body thus formed is ground into a
powder (step S47). Finally, a predetermined pressure is applied to
the resin powder to produce a molding compound resin tablet in
which the phosphor is uniformly dispersed (step S49).
[0053] FIG. 5 shows an embodiment wherein a phosphor powder is
added along with a catalyst and a coupling agent.
[0054] The method of the present embodiment begins from the step of
mixing a translucent liquid resin and a material containing at
least a curing agent (step S51). As the translucent liquid resin
usable in the present invention, an epoxy resin may be mentioned.
Thereafter, a phosphor and other additives are prepared in an
appropriate powder form in the early stage of the mixing step (step
S51), i.e. in a state wherein the curing reaction is not
sufficiently progressed (step S52). Examples of suitable additives
include curing catalysts, coupling agents, release agents and
modifying agents already known in the art. For more uniform mixing,
these additives can be formed together with the phosphor into a
powder through a milling process. Consequently, the phosphor can be
prepared into a powder without undergoing an additional milling
process.
[0055] The mixed powder of the phosphor and the additive thus
prepared are mixed with the translucent liquid resin and the curing
agent (step S53), and then the resulting mixture is subjected to a
kneading process (step S54) in a gel state. As stated above, the
kneading process is preferably performed at a temperature between
about 100.degree. C. and about 120.degree. C. for more uniform
dispersion of the mixture.
[0056] Subsequently, the resulting kneaded mixture is stabilized to
form a molding compound resin body containing the phosphor (step
S55). The molding compound resin body thus formed is a solid state
resin in which the phosphor powder is uniformly dispersed through
the mixing and the kneading processes. As explained above, the
formation of the molding compound resin body is carried out by
quenching the kneaded mixture. Prior to the quenching, the kneaded
mixture may be subjected to a rolling process.
[0057] The molding compound resin body thus formed is ground into a
powder (step S57). Finally, a predetermined pressure is applied to
the resin powder to produce a molding compound resin tablet in
which the phosphor is uniformly dispersed (step S59).
[0058] FIG. 6 shows an embodiment wherein a phosphor powder is
wet-dispersed by a kneading process.
[0059] As explained above, a phosphor powder may be mixed with a
translucent liquid or a mixture having a low curing rate (less than
30%), or may be dispersed in a gelled mixture (e.g., curing rate:
30.about.40%) by a kneading process.
[0060] The method according to the present embodiment begins from
the step of mixing the translucent liquid resin and a material
containing at least a curing agent (step S61). Thereafter, a milled
additive powder is added to the mixture in the early stage of the
mixing step, i.e. in a state wherein the curing reaction is not
sufficiently progressed (step S63). Examples of suitable additives
include curing catalysts, coupling agents, release agents and
modifying agents already known in the art.
[0061] Then, the resulting mixture and a phosphor powder are
subjected to a kneading process (step S64) in a gel state. As
stated above, the phosphor powder prepared in an appropriate powder
form may be added before or during kneading. The phosphor powder is
wet-dispersed in a gelled mixture by a kneading process. This
kneading process is preferably performed at a high temperature of
from about 100.degree. C. to about 120.degree. C. so that the
phosphor powder can be uniformly dispersed in the gelled
mixture.
[0062] Subsequently, the resulting kneaded mixture is stabilized to
form a molding compound resin body containing the phosphor (step
S65). The molding compound resin body thus formed is ground into a
powder (step S67), and is pressurized at a predetermined pressure
to produce a molding compound resin tablet in which the phosphor is
uniformly dispersed (step S69).
[0063] Subsequently, the kneaded mixture is stabilized to form a
molding compound resin body containing the phosphor (step S65). The
solid state molding compound resin body is ground into a powder
(step S67). Finally, a predetermined pressure is applied to the
resin powder to produce a molding compound resin tablet in which
the phosphor is uniformly dispersed (step S69).
[0064] The method for producing a molding compound resin tablet for
wavelength conversion according to the present invention enables
uniform dispersion of a phosphor powder in a mixture for forming a
liquid or gelled resin, thereby producing a molding compound resin
tablet for wavelength conversion which is capable of ensuring
wavelength conversion. In conclusion, the molding compound resin
tablet for wavelength conversion can be advantageously employed in
the formation of a phosphor layer for manufacturing a white light
emitting diode by a transfer molding process.
[0065] That is, according to the method of the present invention, a
phosphor powder is subjected to a wet dispersion process using a
translucent liquid resin to form a molding compound resin body in
which the phosphor powder is dispersed, the molding compound resin
body is ground into a powder, and then the resin powder is
pressurized at a predetermined pressure to form a molding compound
resin tablet. Thereafter, the molding compound resin tablet in
which the phosphor is dispersed is subjected to a transfer molding
process on a package structure on which a blue or UV light emitting
diode is mounted, thereby manufacturing a white light emitting
diode.
[0066] FIG. 7 shows one example of a white light emitting diode 30
manufactured by the method of the present invention. Referring to
FIG. 7, a blue or UV light emitting diode 35 is arranged on a
package substrate 31 in which two lead frames 33 and 34 are formed.
Two electrodes (now shown) of the blue or UV light emitting diode
35 are electrically connected to the lead frames 33 and 34 through
the wires 36 and 37, respectively. The molding compound resin
tablet for wavelength conversion produced in accordance with the
method of the present invention is subjected to a transfer molding
process on the light emitting diode 35 so as to surround the light
emitting diode 35 to form a molding portion 39 for wavelength
conversion on the package substrate 31. Of course, those skilled in
the art will understand that the entire structure of the white
light emitting diode and the shape of the molding portion for
wavelength conversion can be variously modified depending on a
transfer molding apparatus used.
[0067] The molding compound resin tablet for wavelength conversion
produced in accordance with the present invention includes a
phosphor powder uniformly dispersed therein. In addition, the
molding portion 39 for wavelength conversion is formed for a
relatively short curing time by a transfer molding process.
Accordingly, adverse effects due to the precipitation of the
phosphor particles can be avoided.
[0068] The light emitting characteristics of the white light
emitting diode manufactured by the method of the present invention
were compared with those of a white light emitting diode
manufactured by a conventional method.
EXAMPLE
[0069] In accordance with the conventional method shown in FIG. 2,
first an epoxy molding compound resin powder and a YAG-based
phosphor powder were prepared so as to have substantially the same
average particle diameter (about 7 .mu.m), and were then
sufficiently mixed with each other. Thereafter, the mixture was
pressurized to produce an epoxy molding compound resin tablet
containing the phosphor powder. The tablet was subjected to a
transfer molding process to form a molding portion for wavelength
conversion on a package structure employing a light emitting diode
at a wavelength band of 460 nm so as to have a structure similar to
that shown in FIG. 7.
[0070] On the other hand, an epoxy molding compound resin tablet in
which a phosphor powder was uniformly dispersed was produced in
accordance with the method of the present invention shown in FIG.
5. Specifically, a liquid epoxy resin as a base resin was mixed
with a phosphor powder having an average particle diameter of about
7 .mu.m, and then a curing agent was added thereto. During mixing,
a catalyst and a coupling agent were further added and mixed.
[0071] The kind and amount of the curing agent and each additive
used in this Example was identical to those of the curing agent and
each additive employed for the formation of the molding compound
resin used in the conventional method. Next, a kneading process and
a roll milling process were performed on the gelled mixture, and
then the resulting mixture was quenched to produce a solid state
molding compound resin body.
[0072] Subsequently, the resin body was ground into a powder having
an average particle diameter of about 7 .mu.m, and was then
pressurized to produce a molding compound resin tablet in which the
phosphor is uniformly dispersed. The tablet was subjected to a
transfer molding process to form a molding portion for wavelength
conversion on a package structure employing a light emitting diode
at a wavelength band of 460 nm so as to have a structure similar to
that shown in FIG. 7.
[0073] Color region coordinates of each white light emitting diode
manufactured in accordance with the conventional method and this
Example were analyzed. The results are shown in FIGS. 8a and
8b.
[0074] Referring to FIG. 8a, it was confirmed that the color region
of the white light emitting diode manufactured by the conventional
method was broadly distributed on the color coordinate. It was
observed that the white light emitting diode emitted bluish white
light and yellowish white light other than white light. This is
because the tablet was produced in a state wherein the resin and
the phosphor powders were non-uniformly dispersed due to abrasion
between particles upon mixing and/or differences in specific
gravity of the powders.
[0075] On the contrary, as shown in FIG. 8b, the white light
emitting diode manufactured in accordance with this Example was
shown to have a sharp color region (X: 0.28.about.0.30, Y:
0.25.about.0.32). That is, it was confirmed that little or no
bluish white light and yellowish white light was emitted and
substantially all light was converted to white light. This high
light conversion efficiency is because the phosphor powder was
uniformly distributed in the molding compound resin tablet produced
in accordance with the method of the present invention and further
the uniform distribution could be maintained in the transfer
molding process having a relatively short curing time.
[0076] As apparent from the above description, according to the
method of the present invention, since a wet dispersion process
using a translucent liquid resin is employed to produce a molding
compound resin tablet, instead of simple mixing of powders, uniform
dispersion of a phosphor powder in the molding compound resin
tablet can be ensured. In addition, since the phosphor powder can
be uniformly dispersed by a mixing or kneading process for the
formation of a molding compound resin body, without the need for
further processing, the entire production process can be
simplified.
[0077] Furthermore, since the method for manufacturing a white
light emitting diode of the present invention employs the
production method of the molding compound resin tablet, little or
no precipitation of phosphor particles in the molding compound
tablet takes place and uniform dispersion of the phosphor particles
is maintained, thus enabling the manufacture of a white light
emitting diode having high wavelength conversion efficiency.
[0078] The present invention has been described herein with
reference to its preferred embodiments and the accompanying
drawings. These embodiments and drawings do not serve to limit the
present invention, but are set forth for illustrative purposes. The
scope of the present invention is defined by the claims that
follow. Those skilled in the art will appreciate that various
modifications, additions and substitutions are possible, without
departing from the scope and spirit of the invention as disclosed
in the accompanying claims.
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